Aluminium Fatigue

d4v1d sm4rt said:
if the crack is due to being opened against the stop then why are people reporting it on passenger doors which are seldom used?
Click to expand...

I spoke to an Audi technician and he said Audi recons the major cause why the crack develops is when the door is caught by the wind or uncarefully pushed beyond it's natural stop. It's not really metal fatigue. However the door should be designed to withstand such to a limit and is not an excuse.
 
My passenger door has started that clicking noise when closing just like with the drivers only not so bad, I had the drivers door fixed but it only has started making the noise since I had the hinges sorted. Should I take it back to the audi dealer here and tell them?
 
Door repairs

I'm to understand Audi now have the parts? I have not heard anything from my local dealer the said they would call when the parts arrived.
 
Went to mike yesterday he had a look around my hinges, as was not sure what i was looking for, the drivers side just starting to go but the front passenger side a big crack. Went to Grimsby Audi they said they had not heard of this and was very puzzled, came out had alook said don't think that will be covered on age and millage, so i told them to get on the phone because it was, it was nearly 5 and local body shop (Audi approved ) was not answering the phone they would try again tomorrow, local body shop Lincoln 40 miles away
 
The cracking IS covered for ALL A2s, regardless of year, mileage or warranty status.

If anyone is persistantly knocked back by their dealers, please get the following info to me and I'll try to resolve the situation for you:

Dealership name.
Service managers name/workshop controllers name
Contact telephone number

Cheers,

Mike

PS In answer to R8SMVs question, yes, the parts are now available and repairs have been done already.
 
Hello all. Skipton found cracks on both upper hinges of 'Ada' when he was giving the car a professional going over and VAG COM scan. Thanks to all the leg work done by Mike and other forum members, my local Audi Authorised repairer phoned today, having found the relavent Technical Bulletin etc. They will book the car in as soon as confirmation is received from Audi. Again, they quoted Audi as regarding the matter as an 'optical cosmetic issue', or wording very close to that. Apparently any car out of warranty has to be authorised as a 'good will' repair. A formality apparently - (it must be as all A2's must be over 3 years old now!) Either way, a result for me.
Thanks to all involved for the hard work that made my experience straight forward. :)
 
How does the dealer discussion work

"Hi I wonder if you could repair something that isn't effecting my car, but i found in a virtually inaccessible place after going on a forum."

Audi Dealer "What is the problem Sir/madam"

"I have a 1-5mm hair line crack when I rub my finger next to the inside edge of the passenger door hinge"
"Its not urgent, in fact its not an issue at all in terms of safety or visually, as I can't see it really"

Audi Dealer "but..."

"So I would like you to spend 2 days stripping, fixing and repairing my door now that I have found it".

I know I’m mocking this but you have to laugh, I bet the dealers cringe when they hear “I found this on the internet” :D
 
Funny, when I was writing my post I was thinking 'what would Emm have to say about this???' Thanks for being predictable and as free with your opinion as always sir!!! :rolleyes:
 
Sorry i don't fit the mold of anal A2 owner:D

Wait till you see my next post lol
 
Associated post - Door hinge repair success!

Hi all, I'm new to this forum so apologies if this is old news... Just reading about aluminium fatigue and some other associated posts about creaky and cracked A2 door hinges...My drivers door was making a terrible cracking noise when opened and closed so I did some hunting around on the web and found it appeared to be a common issue. I spoke to my local dealer (Norwich Audi) who at first claimed to have not heard of such a problem. I then informed them of an internal Audi bulletin I'd seen on another forum, emailed it to them, and within the same day the parts were on order without my car even being seen!!

I had to wait about 2 weeks for the parts to arrive and Audi have just had the car in for the repairs for 4 days, but all seems well again with my newly replaced hinges! And I didn't have to pay a penny and was given a courtesy car so pleased with service.

Here is the original link and bulletin I sent the main dealer. Hope it is useful to you if your A2 is creaking at the seams!

-------------------------------------------------------------------

Routine durability monitoring by Audi AG has identified a minor cosmetic flaw in the door
hinge of the Audi A2 (model year 2000-2005).
It has been discovered that the hinge can be susceptible to cracks on the outer non-structural
skin.

To some customers this may lead to concern that the structural integrity has been compromised – this is not the case.
Should you receive any customer enquiries relating to this characteristic please advise them that extensive testing of affected hinges by Audi AG has confirmed that their performance and longevity are in no way reduced by these surface cracks.

Replacement doors have been modified since September 2007.
Audi AG have produced a Technical Problem Solution (TPL) which has been published on ELSA -
TPL number 2016707/1. This TPL includes details of how to claim the cost of the repair. Please
note that all vehicles are covered - even if out of warranty - and so customers should not becharged.

However, we do not expect to be in a position to have all the required parts in stock at Dordon until
mid-March. The two part numbers currently unavailable are the kits 8Z0 898 021 and 8Z0 898
022. Please postpone all repairs until all the parts are available. The other parts required are:
• 8Z0 837 349C
• 8Z0 837 350C
• 8Z0 868 243
• DA 001 730 A2
• D 001 001
• D 009 401 04
• N 903 675 03
• N 101 154 04
• 8Z0 898 021 (currently unavailable)
• 8Z0 898 022 (currently unavailable)
As soon as all parts are in stock we will issue a further announcement.

http://www.tyresmoke.net/forum/audi-a2/106191-door-hinge.html#post1293516
 
Thanks. Any chance you have the actual Technical Problem Solution (TPL) or I am asking too much? :)
 
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